Method of fabricating a miniature device having an acoustic diaphragm

Abstract

A method of forming a device having a compliant member includes applying heat to a thermoplastic elastomer to maintain the thermoplastic elastomer in a softened state. The thermoplastic elastomer is extruded in the softened state as a film of thermoplastic elastomer. One or more of a bobbin and a housing, each having and end, is positioned such that the end extends at least partially into the film of thermoplastic elastomer. The positioning occurs when the thermoplastic elastomer is in the softened state and/or the bobbin and/or housing is at a temperature that is greater than a temperature of the film of thermoplastic elastomer. The film is cooled so that the bobbin and/or housing are secured to the film and so that the thermoplastic elastomer is in a state that exhibits rubber-like properties.

Description

RELATED APPLICATIONS

This application is a continuation application of U.S. Non-Provisional patent application Ser. No. 15/661,155, filed Jul. 27, 2017, and entitled “METHOD OF FABRICATING A MINIATURE DEVICE HAVING AN ACOUSTIC DIAPHRAGM,” the contents of which are incorporated herein in its entirety.

BACKGROUND

This disclosure relates to a miniature device having a compliant member. More particularly, the disclosure relates to a method of fabricating an acoustic diaphragm on the miniature device.

SUMMARY

In one aspect, a microspeaker device includes an acoustic diaphragm, a housing, a bobbin and a coil. The acoustic diaphragm is formed of a film of thermoplastic elastomer. The housing has an end extending at least partially into the film of thermoplastic elastomer, wherein the film adheres to a portion of the housing at the end of the housing to form a first meniscus along a portion of a wall of the housing. The bobbin has a bobbin surface and is disposed inside the housing. The bobbin has an end extending at least partially into the film of thermoplastic elastomer, wherein the film adheres to a portion of the bobbin at the end of the bobbin to form a second meniscus along a wall of the bobbin. The coil is wound on the bobbin surface.

Examples may include one or more of the following features:

The first meniscus may include a first inner meniscus having a height along an inner wall surface of the housing and a first outer meniscus having a height along an outer wall surface of the housing and the second meniscus may include a second inner meniscus having a height along an inner wall surface of the bobbin and a second outer meniscus having a height along an outer wall surface of the bobbin.

The axis of the housing and an axis of the bobbin may be colinear. The housing may be a tube having an opening at the end.

The thermoplastic elastomer may include a thermoplastic vulcanizate or a styrenic-based thermoplastic elastomer. The thermoplastic elastomer may have a hardness of less than 15 Shore A. The thermoplastic elastomer may have a Young's modulus of less than 0.25 megapascals. The film of thermoplastic elastomer may include an annular area defining a compliant surround about the acoustic diaphragm.

In accordance with another aspect, a microspeaker device includes an acoustic diaphragm, a housing, a bobbin and a coil. The acoustic diaphragm has a substantially planar shape and formed of a film of thermoplastic elastomer. The housing has an end extending at least partially into the film of thermoplastic elastomer, wherein the film adheres to a portion of the housing at the end of the housing. The bobbin has a bobbin surface and is disposed inside the housing. The bobbin has an end extending at least partially into the film of thermoplastic elastomer, wherein the film adheres to a portion of the bobbin at the end of the bobbin. The coil is wound on the bobbin surface.

Examples may include one or more of the following features:

The film may adhere to a portion of the housing at the end of the housing to form a meniscus along a portion of a wall of the housing. The film may adhere to a portion of the bobbin at the end of the bobbin to form a meniscus along a wall of the bobbin.

The film may adhere to a portion of the housing at the end of the housing to form a first inner meniscus having a height along an inner wall surface of the housing and a first outer meniscus having a height along an outer wall surface of the housing and the film may adhere to a portion of the bobbin at the end of the bobbin to form a second inner meniscus having a height along an inner wall surface of the bobbin and a second outer meniscus having a height along an outer wall surface of the bobbin.

An axis of the housing and an axis of the bobbin may be colinear. The housing may be a tube having an opening at the end.

The thermoplastic elastomer may include a thermoplastic vulcanizate or a styrenic-based thermoplastic elastomer. The thermoplastic elastomer may have a hardness of less than 15 Shore A. The thermoplastic elastomer may have a Young's modulus of less than 0.25 megapascals.

The film of thermoplastic elastomer may include an annular area defining a compliant surround about the acoustic diaphragm.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of examples of the present inventive concepts may be better understood by referring to the following description in conjunction with the accompanying drawings, in which like numerals indicate like structural elements and features in various figures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of features and implementations.

FIG. 1A, FIG. 1B and FIG. 1C are a perspective illustration, a perspective cutaway illustration and an exploded cutaway illustration, respectively, of an example of a microspeaker for a miniature earbud.

FIG. 2 is a flowchart representation of an example of a method 100 of fabricating a device having a compliant member.

FIG. 3A is a cross-sectional side view of an example of a thermoplastic elastomer film on a release liner.

FIG. 3B shows end portions of a housing and a bobbin extending into a thermoplastic elastomer film.

FIG. 3C shows the thermoplastic elastomer film of FIG. 4B that remains as a substantially planar compliant member after the release liner is removed.

FIG. 4 is a graphical representation of how the storage modulus of an example of a thermoplastic elastomer material varies as a function of temperature.

FIG. 5 shows a magnified cross-sectional view of a portion of the ends of the housing and bobbin corresponding to the left side of FIG. 3C.

FIG. 6 is a flowchart representation of another example of a method of fabricating a device having a compliant member.

FIG. 7 is a flowchart representation of another example of a method of fabricating a device having a compliant member.

DETAILED DESCRIPTION

Modern in-ear headphones, or earbuds, typically include microspeakers. The microspeaker may include a coil that is attached to an acoustic diaphragm either directly or through a bobbin on which the coil is wound. Motion of the diaphragm due to an electrical signal provided to the coil results in generation of an acoustic signal that is responsive to the electrical signal. The microspeaker typically includes a housing, such as a sleeve or tube, which encloses the bobbin, coil and a magnetic structure. As the size of the earbud decreases, it becomes increasingly difficult to fabricate the acoustic diaphragm with an elastic suspension at one end of the bobbin (or coil) and housing.

FIG. 1A, FIG. 1B and FIG. 1C are a perspective illustration, a perspective cutaway illustration and an exploded cutaway illustration, respectively, of an example of a microspeaker 10 that can be used in a miniature earbud. The microspeaker 10 includes a cylindrical housing 12 having an opening at both ends. Inside the housing 12 is a bobbin 14 that is nominally cylindrical in shape and which is open at least at one end. The housing 12 and bobbin 14 are secured at one of their ends to a compliant member 16. In some examples, the housing 12 is made of stainless steel and the bobbin 14 is made of a polyimide (e.g., KAPTON®) or polyethylene terephthalate (PET) (e.g., MYLAR®). A magnet assembly 18 is secured to a platform 19 at an end of the housing 12 that is opposite to the compliant member 16. The magnet assembly 18 includes two magnet pieces 18A and 18B separated by a coin 18C. The magnet assembly 18 extends along an axis 20 of the housing 12 and into an open region inside the bobbin 14. In one example, the magnet pieces 18A and 18B are cylindrical neodymium magnets. A coil 22 is wound onto an outside surface of the bobbin 14. The bobbin 14 has an axis that is colinear with the housing axis 20. The bobbin 14 moves substantially along the housing axis 20 in response to an electrical current conducted through the coil 22. In turn, a central circular portion of the compliant member 16 moves axially and displaces air to thereby create an acoustic signal.

In one technique for fabricating a compliant member, an open end of a housing and an open end of a bobbin are placed into a single thin layer of liquid silicone rubber. The liquid silicone rubber is then cured to form the compliant member. The central region of the compliant member that is located within the end region of the bobbin can be stiffened while the annular region that surrounds the central region remains compliant. Difficulties arise with this technique as the liquid silicone has a surface tension that causes the liquid to adhere to and “climb up” the walls of the housing and the bobbin to form menisci. The migration of the liquid silicone along the walls can occur quickly, for example, within a few seconds of placing the ends of the housing and bobbin into the liquid silicone rubber. The result of the migration is a reduction in the thickness of the cured layer of silicone which can lead to holes in the compliant member. Holes can form during the demolding process because the compliant member is weakened at the thinned areas. In addition, thinned areas may result in holes being formed in the compliant member or tearing of the compliant member during operation of the microspeaker.

One method for fabricating the compliant member is described in U.S. patent application Ser. No. 15/182,069, filed Jun. 14, 2016, the disclosure of which is incorporated herein by reference in its entirety. According to the method, which is based on a two-pass silicone film casting process, a second elastomeric layer is applied to a thicker and at least partially cured first elastomeric layer. This method results in a reduction of the thinning of the full elastomeric layer. A corresponding reduction in the formation of holes during demolding and tearing during microspeaker operation is achieved.

According to another method for fabricating the compliant member, as described in U.S. patent application Ser. No. 15/598,065, filed May 17, 2017, the disclosure of which is incorporated herein by reference in its entirety, a single pass elastomeric layer casting process is employed. In this method, the viscosity of the layer is controlled during fabrication by appropriate application of heat or ultraviolet (UV) light in a manner that limits the migration of the liquid silicone along the walls of the housing and bobbin, and the height of the resulting menisci formed along the walls. Consequently, occurrences of hole formation and tearing may be further reduced.

The above referenced methods have associated challenges, including cost, complexity and material availability. For example, control of the viscosity of the elastomeric materials during the fabrication processes using heat or UV light can be difficult. In addition, silicones or other soft thermoset elastomers such as polyurethanes can be expensive and may not be commercially available. Furthermore, various elastomeric materials may have limited shelf-life (e.g., a few months); requiring repurchase of the material while an unused portion of a prior purchase amount may have expired. Moreover, the time needed to complete the fabrication process can be extensive. For example, the thermoset elastomeric material may require extended curing times (e.g., two hours or more).

In examples described herein for a method of fabricating a device having a compliant member, heat is applied to a thermoplastic elastomeric material to change the material to a softened state and/or maintain the material in a softened state. As used herein, a “softened state” means that the material is easily shaped through the application of heat and/or pressure. When in a softened state, the material is above its glass transition (T_g) and may exhibit behavior similar to that of a molten material. The softened material is extruded into a film, and a bobbin and/or housing are positioned such that their ends extend at least partially into the film. The positioning may occur while the film of thermoplastic elastomer is in the softened state. Alternatively, the bobbin and/or housing may be heated to a temperature that is greater than the temperature of the film before the bobbin and/or housing are positioned in the film. The film with the bobbin and/or housing is cooled so that the thermoplastic elastomer is no longer softened but instead is in a “rubber state” in which the thermoplastic elastomer exhibits rubber-like properties. During the transition from the softened state to the rubber state, the bobbin and/or housing is secured to the film.

Thermoplastic elastomers combine elastomeric properties with advantages of thermoplastics and can typically be processed and shaped using techniques similar to those used for thermoplastics. In some instances, thermoplastic elastomers are block copolymers with elastomers and can be used as a replacement for vulcanized rubbers. Advantageously, thermoplastic elastomers have inherently high viscosity and, unlike techniques utilizing other types of elastomeric materials for forming compliant members, no extended heating period is necessary for curing. Instead, the application of heat is limited to that appropriate to cause the material to flow as thermoplastic elastomers generally have higher melt viscosities than thermoset rubbers.

Some thermoplastic elastomers having a hardness from about 15 Shore A to about 90 Shore A and therefore may be too stiff for obtaining a sufficiently compliant member; however, other thermoplastic elastomers, such as oil extended thermoplastic elastomers, can be used. For example, thermoplastic elastomers having a hardness of less than 15 Shore A and/or a Young's modulus of less than 0.25 MPa can be used.

By way of example, the thermoplastic elastomer may be a thermoplastic vulcanizate (TPV) such as Sarlink® from Teknor Apex Company, Pawtucket, R.I. In an alternative example, the thermoplastic elastomer may be a styrenic-based thermoplastic elastomer such as Medalist® MD-16120G or Medalist® MD-447 from Teknor Apex. In another example, the thermoplastic elastomer may be a derivative, such as an α-methyl styrene-based thermoplastic elastomer.

FIG. 2 is a flowchart representation of an example of a method 100 of fabricating a device having a compliant member. Reference is also made to FIGS. 3A to 3C which are cross-sectional side view illustrations showing, in a sequential manner, the method 100 as applied to fabrication of a microspeaker device in which the compliant member can subsequently be processed to form an acoustic diaphragm and a surround.

According to the method 100, heat is applied (110) to a thermoplastic elastomer (TPE) to achieve and maintain the thermoplastic elastomer in a softened state. If a styrenic-based thermoplastic elastomer is used, the heat applied is sufficient to heat the thermoplastic elastomer greater than the glass transition temperature T_g of the styrenic component (e.g., greater than 100° C.) at which the material begins to soften. If a thermoplastic vulcanizate is used, the applied heat is sufficient to heat the material to a temperature greater than the crystalline melting temperature T_m of the polypropylene component (e.g., greater than 160° C.).

Reference is also made to FIG. 4 which shows the storage modulus of an example thermoplastic elastomer material (Medalist® MD-447 medical elastomer) as a function of temperature. The material has a substantially constant storage modulus value from below room temperature to greater than 100° C. At higher temperatures, the storage modulus decreases and the material transitions from a rubber state to a softened state with increasing temperature. The thermoplastic elastomer is extruded (120) to form a sheet or film on a release liner. For example, the thermoplastic material corresponding to FIG. 4 may be at a temperature of approximately 125° C. or greater during extrusion.

FIG. 3A is an example cross-sectional side view of a thermoplastic elastomer film 22 on a release liner 24. The thermoplastic elastomer material may be provided as a granulate (e.g., pellets) and fed by an extrusion screw under application of heat (e.g., increase temperature of thermoplastic elastomer material to between 190° C. and 200° C.). The softened thermoplastic elastomer is extruded through a die onto the release liner 24. A housing and bobbin are then positioned (130) on the film 22 so that one end of each extends at least partially into the film 22. For example, FIG. 3B shows a housing 28 and bobbin 30 (only end portions illustrated) with their ends extending at least partially into the thermoplastic elastomer film 22. In one example, the housing 28 is in the form of a hollow cylindrical tube and the bobbin 30 is configured to move in a bi-directional manner along the tube axis. The housing 28 and bobbin 30 may be positioned at the same time. Alternatively, the housing 28 and bobbin 30 may be positioned at different times as long as the thermoplastic elastomer film 22 is in a softened state. Due to the inherently higher viscosity of a thermoplastic elastomer in a softened state relative to an uncured elastomeric material, the migration of the thermoplastic elastomer is substantially reduced relative that of the uncured elastomeric material. The reduction in material migration results in smaller menisci formed along the walls of the housing 28 and bobbin 30 as described further below. The thermoplastic elastomer film 22 with the embedded housing 28 and bobbin 30 is then cooled (140) so that the film 22 transitions to a rubber state and the housing 28 and bobbin 30 are secured to the film 22. Passive cooling may be used. Alternatively, active cooling can be employed to decrease the manufacturing time.

The release liner 24 is removed (150) so that the thermoplastic elastomer film 22 remains as a substantially planar compliant member that adheres to the end of the housing 28 and the bobbin 30 as shown in FIG. 3C. The central region of the compliant member, (i.e., the area defined within the diameter of the bobbin 30) can be stiffened to form the acoustic diaphragm. The annular area surrounding the central region defines a compliant surround that can support the bobbin 30 and coil, and enables the acoustic diaphragm to move axially to thereby generate an acoustic signal. The portion of the compliant member that extends beyond the outer diameter of the housing 28 may be removed (160) by any of a variety of techniques such as by trimming or using a punch tool.

FIG. 5 shows a magnified cross-sectional view of a portion of the ends of the housing 28 and bobbin 30 corresponding to the left side of FIG. 3C. A meniscus 32 is formed at locations where the thermoplastic elastomer film material has climbed (vertical migration in the figure) the walls of the housing 28 and bobbin 30. Thus, there is an inner meniscus 32A and an outer meniscus 32B along an inner wall surface 34 and an outer wall surface 36, respectively, of the housing 28. Similarly, there is an inner meniscus 32C and an outer meniscus 32D along an inner wall surface 38 and an outer wall surface 40, respectively, of the bobbin 30. Each meniscus 32 has a height H1 defined from the top surface 42 of the thermoplastic elastomer film 22. The menisci 32 are formed during a period starting when the ends of the housing 28 and bobbin 30 are first positioned in the softened thermoplastic elastomer film 22. All menisci 32 are shown as having the same height H1; however, the heights along the two walls may differ due to a difference in material migration along the walls according to differences in the wall materials. The bottoms of the walls are not coincident with the bottom of the thermoplastic elastomer film 22 as there is some affinity between the thermoplastic elastomer material and the wall regardless of the viscosity of the thermoplastic elastomer while in the softened state.

Due to the higher viscosity of the thermoplastic elastomer film 22 and the corresponding reduction in material migration, the height H1 of the menisci 32 is substantially less than a height H2 of the menisci that otherwise would have formed using an uncured elastomeric layer. As a result, less thinning occurs and there is a substantial reduction in thickness variations across the thermoplastic elastomer film 22. Advantageously, the fabricated device is easier to remove from the release liner (not shown) without tearing or generating holes. Moreover, the opportunity for holes or tears to be generated during operation of a microspeaker device fabricated with the compliant member is reduced or eliminated. An additional advantage is a more consistent stiffness of the suspension defined by the peripheral portion of the compliant member that surrounds the inner acoustic diaphragm.

It should be noted that the elimination of the menisci 32 is not a goal as they represent an increased area of adherence to the walls of the housing 28 and bobbin 30, and tearing can occur when the release liner is removed if no menisci are present. In addition, the menisci 32 limit the stress concentration at the joint between the elastomer and the housing and bobbin walls.

Reference is again made to U.S. patent application Ser. No. 15/182,069 which discloses a two-pass film casting process for forming the compliant member in which a second elastomeric layer is applied to a thicker and at least partially cured first elastomeric layer. The process achieves advantages over methods based on a single elastomeric layer; however, the methods described herein using a thermoplastic elastomer achieve additional advantages over the two-pass film casting technique due in part to the use of processes that can be implemented with standard plastics processing equipment and readily-available materials. Moreover, a lower cost is realized by avoidance of curing processes and the related equipment costs, labor costs and manufacturing delay. A further advantage of the examples of methods described herein includes low surface tack which eliminates the need for a specialized coating on the release liner to facilitate separation from the thermoplastic elastomer film. Moreover, in contrast to thermoset elastomers, thermoplastic elastomer materials generally are not subject to short expiration periods during which the materials must be used.

FIG. 6 is a flowchart representation of an alternative example of a method 200 of fabricating a device having a compliant member. According to the method 200, heat is applied (210) to a thermoplastic elastomer to achieve and maintain the thermoplastic elastomer in a softened state. The thermoplastic elastomer is extruded (220) to form a sheet or film on a release liner. The thermoplastic elastomer film and release liner are cooled (230) (e.g., passively cooled to ambient temperature) so that the thermoplastic elastomer film transitions to a rubber state. Optionally, the thermoplastic elastomer film and release liner may be wound on a roll or packaged in another configuration for convenient transport in a situation where subsequent fabrication is to occur at a different location. The thermoplastic elastomer film and release liner are heated (240) so that the thermoplastic elastomer changes to a softened state and the bobbin and housing are then positioned (250) in the softened thermoplastic elastomer film. Subsequently, the thermoplastic elastomer film, release liner, bobbin and housing are cooled (260) to thereby return the film to a rubber state and secure the bobbin and housing to the film. The release liner is then separated (270) from the thermoplastic elastomer film and the excess film, that is, the film that extends beyond the diameter of the housing, is removed (280).

In one specific example, steps 210 through 230 are performed at one facility where extrusion equipment is located and the resulting thermoplastic elastomer film and release liner are shipped to a different location where the remaining method steps are performed.

FIG. 7 is a flowchart representation of another example of a method 300 of fabricating a device having a compliant member. Similar to the examples described above, heat is applied (310) to change a thermoplastic elastomer to a softened state and the softened material is extruded (320) to form a film on a release liner. The thermoplastic elastomer film and release liner are cooled (330) so that the thermoplastic elastomer film transitions to a rubber state. Unlike the prior method examples, the bobbin and housing are heated (340) to a temperature substantially greater than the temperature of the thermoplastic elastomer film before being positioned (350) in the film. For example, the bobbin and housing may be heated to a temperature between approximately 190° C. and 210° C. The temperatures of the bobbin and housing are sufficiently high such that the thermoplastic material in contact with and near to the bobbin and housing changes to a softened state due to conduction of thermal energy from the heated parts. Consequently, the bobbin and housing extend at least partially into the film. The bobbin and housing are then cooled (360), either actively or passively, to secure them to the film. Subsequently, the release liner is separated (370) from the film and the film extending beyond the outer diameter of the housing is removed (380).

A number of implementations have been described. Nevertheless, it will be understood that the foregoing description is intended to illustrate, and not to limit, the scope of the inventive concepts which are defined by the scope of the claims. Other examples are within the scope of the following claims.

Claims

1. A microspeaker device comprising:

an acoustic diaphragm formed of a film of thermoplastic elastomer;

a housing having an end extending at least partially into the film of thermoplastic elastomer, wherein the film adheres to a portion of the housing at the end of the housing to form a first meniscus along a portion of a wall of the housing;

a bobbin having a bobbin surface and being disposed inside the housing, the bobbin having an end extending at least partially into the film of thermoplastic elastomer, wherein the film adheres to a portion of the bobbin at the end of the bobbin to form a second meniscus along a wall of the bobbin; and

a coil wound on the bobbin surface.

2. The microspeaker device of claim 1 wherein the first meniscus comprises a first inner meniscus having a height along an inner wall surface of the housing and a first outer meniscus having a height along an outer wall surface of the housing and wherein the second meniscus comprises a second inner meniscus having a height along an inner wall surface of the bobbin and a second outer meniscus having a height along an outer wall surface of the bobbin.

3. The microspeaker device of claim 1 wherein an axis of the housing and an axis of the bobbin are colinear.

4. The microspeaker device of claim 1 wherein the housing is a tube having an opening at the end.

5. The microspeaker device of claim 1 wherein the thermoplastic elastomer comprises a thermoplastic vulcanizate.

6. The microspeaker device of claim 1 wherein the thermoplastic elastomer comprises a styrenic-based thermoplastic elastomer.

7. The microspeaker device of claim 1 wherein the thermoplastic elastomer has a hardness of less than 15 Shore A.

8. The microspeaker device of claim 1 wherein the thermoplastic elastomer has a Young's modulus of less than 0.25 megapascals.

9. The microspeaker device of claim 1 wherein the film of thermoplastic elastomer includes an annular area defining a compliant surround about the acoustic diaphragm.

10. A microspeaker device comprising:

an acoustic diaphragm having a substantially planar shape and formed of a film of thermoplastic elastomer;

a housing having an end extending at least partially into the film of thermoplastic elastomer, wherein the film adheres to a portion of the housing at the end of the housing;

a bobbin having a bobbin surface and being disposed inside the housing, the bobbin having an end extending at least partially into the film of thermoplastic elastomer, wherein the film adheres to a portion of the bobbin at the end of the bobbin; and

a coil wound on the bobbin surface.

11. The microspeaker device of claim 10 wherein the film adheres to a portion of the housing at the end of the housing to form a meniscus along a portion of a wall of the housing.

12. The microspeaker device of claim 10 wherein the film adheres to a portion of the bobbin at the end of the bobbin to form a meniscus along a wall of the bobbin.

13. The microspeaker device of claim 10 wherein the film adheres to a portion of the housing at the end of the housing to form a first inner meniscus having a height along an inner wall surface of the housing and a first outer meniscus having a height along an outer wall surface of the housing and wherein the film adheres to a portion of the bobbin at the end of the bobbin to form a second inner meniscus having a height along an inner wall surface of the bobbin and a second outer meniscus having a height along an outer wall surface of the bobbin.

14. The microspeaker device of claim 10 wherein an axis of the housing and an axis of the bobbin are colinear.

15. The microspeaker device of claim 10 wherein the housing is a tube having an opening at the end.

16. The microspeaker device of claim 10 wherein the thermoplastic elastomer comprises a thermoplastic vulcanizate.

17. The microspeaker device of claim 10 wherein the thermoplastic elastomer comprises a styrenic-based thermoplastic elastomer.

18. The microspeaker device of claim 10 wherein the thermoplastic elastomer has a hardness of less than 15 Shore A.

19. The microspeaker device of claim 10 wherein the thermoplastic elastomer has a Young's modulus of less than 0.25 megapascals.

20. The microspeaker device of claim 10 wherein the film of thermoplastic elastomer includes an annular area defining a compliant surround about the acoustic diaphragm.